Mattress



April 22 P. C. BEDNAREK MATTRESS Filed Sept. 10 1921 2 Sheets-Sheet l Patented Apr. 22, 1924.

wire '1 PETER C. BEDNAREK, OF CHICAGO, ILLINOIS.

MATTRESS.

7 '0 ail whom it may concern:

Be it known that 1, PETER C. BEDNAREK,

a citizen of the United States, residing at Chicago, in the county of Cook and State of Illinois, have invented a new and useful Improvement in Mattresses, of which the following is a specification.

My invention relates, "more particularly,

to mattresses of the so called tufted type;

and my primary objects, generally stated,

are to provide a novel and inexpensive construction of mattress which shall be highly sanitary, and will hold its shape, and other objects as will be manifest from the following description.

Referring to the accompanying drawings:

Figure 1 is a plan view of a mattress embodying'my invention. Figure 2 is an edge view thereof. Figure 3 is an edge View of the interior of the mattress, showing a portion of the inner casing broken away, this view showing the interior portion of the mattress before being tufted. Figure 4 is a view like Fig. 3 of the structure therein shown, showing the latter in tufted condition. Figure 5 is an enlarged section taken at the line 5-5 on Fig. 1, and viewed in the direction of the arrows. Figure 6 is a view in elevation of the side of the mat- :ao tress casing. Figure 7 is an enlarged 'section of the structure of Fig. 6, taken at the line 7-7 on Fig. 1 and viewed in the direction of the arrows. Figure8 is an enlarged cross-sectional view of the structure taken through the tufting means, and showing the manner of assembling the outer casing with the interior structure. Figure 9 is an enlarged broken section showing, in detail, the manner of connecting the outer casing with the interior structure; and Figure 10, a broken section taken at the line 10-10 on Fig. 9 and viewed in the direction of the arrows.

In the constructing of am'attress as shown in the drawings, I provide filling material, represented at 11, which may be of any desirable character, such as felt as is commonly provided in mattresses, though it will be understood that any other desirable filling material maybe employed, the filling, especially where it is of felt as stated, or of such other material as to render itdesirable, being enclosed within a covering represented at 12 which may be of muslin or any other suitable material. The cover- 12 is made preferably of thesameshape as the mattress to be produced and completely encloses the filling 11. The mattress shown also comprises an outer casing, rep-- resented at 13, and which may be of ticking, or any. other suitable material completely housing the filling 11 and its covering 12, the entire mattress structure being caused to present a tufted appearance as hereinafter explained.

In the manufacture of the mattress shown, after forming the internal structure of the mattress, comprising the filling 11 and the covering 12,-this part of the mattress being shown in Fig. 3, the structure thus formed is tufted at intervals, as by the employment of tufting cords represented at 1 1', these cords being passed through the covering 12 and filling 11 first in one direction and then in the opposite direction, the ends of the cord being tied tightly together, as repre sented at 15, and the cords'drawn up sufficiently tightly to produce the desired tufting at intervals of the structure of Fig. 3, which latter assumes the general contour in elevation as shown in Fig. 4, each tufting cord, in the structure shown, for each point of tufting, being separated from the others thereof.

The casing 13 is constructed separate from the'otherpart of the mattress just described, its upper and lower sides, represented at 16 and 17, respectively, which form the top and bottom of the mattress, being preferably formed from separate lengths of goods, separate from those forming the surrounding sides of tne mattress. Before being sewed to the surrounding side portions-of the casing 13 each separate length of goods to form the upper and lower portions 16 and 17 therefore, respectively, is folded upon itself, in a direction crosswise of the length of the goods, and stitched along the line 23 preferably throughout the width of 'the goods, to form pleats 18 which are spaced apart a distance substantially equal to the spacing apart of the several rows oftufting of the structure of Fig. 4;, these pleats in the finished structure extending crosswise of the mattress andcoincident with the several rows of tuft ing referred to. In forming the casing 13 as stated, one end thereof is left open, and in the assembling of this casing with the part of the mattress of Fig. 4, the latter is inserted into the open end of the casing to a oosition in which it extends into close enagement with the closed end of the casing,

the latter being folded back upon itself as shown in Fig. h, to expose the internal folds, as represented at 19, of the pleat nest adjacent the closed end of the casing 13 at both the top and bottom surfaces of the mattress. With the parts in this position the casing 13 is fastened to the tufted structure of Fig. latpoints coincident with the tufting of the letter at both the top and bottom surfaces of the mattress, as by means of the cords represented at 20 which are threaded through the portions 19 of the pleats and through the portions of the pleats, represented at 22, located at the inner sides of the portions 19 at opposite sides of the mattress, and also through the covering 12 and looped through the opposite end portions of the tufting ties 1%, as clearly shown inFigs. 9 and 10, as to the casing section 16, the free ends of the cords 20 being tightly tied together as represented at 21, it being noted that the cords 2O engage the casing 13 at the portions of the pleats located beyond the stitching 23 by means of which the pleats are maintained. The casing 18 having been tied down, stated, at intervals along the first line of tufting at each face of the mattrcss, the operator by drawing upon the free end of the casing 13, in a direction reverse to that of folding the casing backwardly as hereinbefore stated, causesthe casing to be drawn to a position in which its next row of pleats 18 at opposite faces thereof, coincides with the next row of tufting of the structure of Fig. t at each face thereof, whereupon the operator tics down the casing at points coincident *ith the points of tufting as hereinbefore explained, the operations just stated being continued in succession, until the casing completely houses the interior structure of the mattress and has been tied down to this structure at each point of tufting, at both the upper and lower faces of the mattress, the operator then sewing up the open end of'the casing to complete the enclosure. After forming the structure as stated it is, by preference, stitched along its upper and lower marginal edges to form the edge rolls represented at 24:, in accord ance with common practice in the manufacture of mattresses.

By preference the interior structure shown in Fig. i is constructed of slightly greater dimensions than the casing 13, and the latter, considered as a structure before assembly with the interior structure of Fig. 4c, is constructed of a size slightly larger than the mattress to be produced, more particularly to compensate for the drawing up of the parts of the casing 13 in the stitching of the rolls 24.

It is well known that it is highly desirable, in the manufacture of mattresses, especially where the filling is of felt, that the means by which the filling is tufted, should be drawn. quite ti htly to firmly compress the filling at the points of tufting, with the result that the mattress structure is caused to pres nt relatively deep depressions in its opposite surfaces at the tufting portions, this being necessary in order that the filling material shall not be readily displaceable in the use of the mattress and the tufted appearance maintained. On the other hand it is undesirable that the casing be tufted to the degree required of the filling, inasmuch as under continued use of the mattress, the filling becomes more or less compacted and set in this condition which causes the upper and lower portions of the mattress casing to straighten out and, augmented by the stretch of the goods itself, produce unsightly distortion of the mattress. According to the preferred illustrated embodiment of my invention, while the filling is tufted t0 the desired extent, the upper and lower surfaces 16 and 17 of the mattress casing are tufted to a lesser degree, but nevertheless to a sufficient degree to present the desired tufted'appearance of the finished mattress. Thus liability of the mattress becoming distorted by compacting of the filling by con tinued use of the mattress, is reduced to the minimum, the stretching of the goods of which the portions 16 and 17 are made, being reduced to the minimum by reason of the transverse lines of stitching 23 forming the pleats 18. Furthermore, it will be noted, while the opposed surfaces of the mattress present a desirable tufted appearance, the tufting means, by Virtue of the provision of the pleats as stated, are caused to be covered by the outermost folds of the pleats, and thus the tufted exterior of the mattress does not present such places for lodgment of dirt and dust as to render difficult the cleaning of the mattress cover, the surfaces presented being practically unbroken. and permitting of the ready removal of dust.

While I have illustrated and described a particular construction embodying my invention, I do not wish to be understood as intending to limit it thereto, as the same may be variously modified and altered Without departing from the spirit of my invention.

What 1 claim as new, and desire to secure by Letters Patent, is:

1. A mattress formed of a casing, filling therein, and means tufting said filling and effecting a tufted appearance of said casing, said casing being formed with pleats, with the engagement of said means with said casing being at the underlying portions of said pleats, whereby said means are covered.

2. A mattress having a casing, filling enclosed in said casing, cords, or the like, extending through said filling at intervals and tufting the latter, said casing being formed with pleats, and means effecting a tufted appearance of said casing engaging the latter at said pleats and covered by the latter.

3. A mattress having a casing, filling, a covering for said filling and enclosed in said casing, means tuftingsaid filling and covering, and separate means effecting a tufted appearance of said casing and covered by the latter.

4. A mattress having a casing, filling, a covering for said filling and enclosed in said casing, means tufting said filling and covering, and separate means effecting a tufted appearance of said casing, said casing being formed with pleats with portions of which said last nan1ed means engage, said lastnamed means being covered by said casing.

5. A mattress formed of a casing stitched at intervals to form pleats, filling in said casing, and means tufting said structure, said means engaging underlying portions of said pleats and covered by the outer portions of said pleats.

6. A mattress formed of an outer casing, filling therein, tufting cords engaging said filling at intervals to cause said filling to be tufted independently of said casing, and means engaging said casing and looped through said tufting cords for causing said casing to present a tufted appearance.

7. A mattress formed of an outer casing stitched at intervals to form pleats extending in generally parallel relation, filling, an inner casing enclosing said fillingand located within said outer casing, tufting cords, or the like, extending at intervals through said inner casing and filling and drawn comparatively tightly to cause said inner casing and filling to present a tufted appearance, and cords, or the like, engaging said outer casing at points coincident with the tuftin of the said filling and inner casing an looped through said first-referred-to cords, or the like, to cause said outer casing to present a tufted appearance, said second-named cords, or the like, extending throughthe inner portions of said pleats, whereby the outer portions of said pleats cover said lastnamed cords, or the like.

8. A mattress having a casing, filling, means tufting said filling, and means effecting a tufted appearance of said casin said casing being formed with pleats stitc ed to position and extending coincident with the points of tufting.

9. A mattress having a casing, filling, means tufting said filling, and means efiecting a tufted appearanceof said casing, said casing being formed with pleats stitched to position, said last-named means engaging the covered portions of said pleats.

10. A mattress comprising a tufted filling,

and a casing enclosing said filling, said cas-,

ing being formed with pleats extending substantially parallel with each other and entirely across the casing and coincident with the points of tufting, said casing being depressed, and held in such condition, at points coincident with the points of tufting.

PETER C. BEDNAREK. 

